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1. Turn off the ignition switch before proceeding. 2. Select a convenient mounting location for the Bosch sensor. In general, the sensor should be mounted as close to the exhaust valve or exhaust manifold as practical. When choosing a mounting location, allow several inches clearance for the sensor wire harness. The wire harness must exit straight out from the sensor. Do not loop the harness back onto the sensor body. The sensor responds to oxygen pressure. Excessive backpressure will cause a reading error. For turbocharged applications, you must mount the sensor downstream of the turbo. 3. For temporary use during dyno tuning, you can mount the Bosch wide-band sensor in place of one of the original equipment rear oxygen sensors (after the catalytic converter). You can also use a sniffer in the tailpipe. For permanent mounting, an 18 x 1.5 mm weld nut must be welded onto the exhaust pipe. After welding, run an 18 x 1.5 mm tap through the threads. Failure to clean the threads may result in sensor damage. Note that most automotive muffler shops are familiar with oxygen sensor weld nut installation on custom pipes. Do not install the sensor until after the free air calibration procedure described in the following section. Always use an anti-seize lubricant such as Permatex 133A on the sensor threads. 4. Install the WEGO IV unit where the display will be visible during testing. The unit is not sealed and must be mounted in a dry location away from sources of heat. We recommend underdash mounting or use in a dyno lab environment. The unit is not intended for underhood mounting. The unit can be secured by means of Velcro tape strips. Use nylon tie wraps to secure the wire harness near the unit. 5. Working with clamping terminal blocks . All connections to the WEGO IV terminal block must be clearly identified either by means of distinct wire colors (such as shown in Figure 1) or wire labels. If you use different wire colors, mark up Figure 1 for future reference. All connections can be made with 18-20 AWG wire. Wire should be stripped back

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1. Block motorcycle underneath frame so front wheel is raised off the ground. 2. See Figure 1. Remove the upper (1) and lower (2) brake caliper mounting bolts and brake caliper(s) (3). Support caliper(s) using a rubber bungee cord. Be careful not to scratch fender paint. NOTES Do not operate front brake lever with the front wheel removed or the caliper piston may be forced out of piston bores. Reseating the piston requires disassembly of the caliper. Prior to removal, make note of existing left and right spacer location. The new spacers will be installed in the locations. 3. See Figure 3. On left side of wheel, remove axle nut (D), lockwasher (E) and washer (F). Perform the following: 4. Sportster and Dyna (except FXDWG) See Figure 2. Loosen the pinch bolt nut (1) and pull the the axle (2) free. Remove wheel and spacers. Leave bearing(s) in place. Discard spacers. 3 1 2 is04469 1. Brake caliper mounting bolt, long (top) 2. Brake caliper mounting bolt, short (bottom) 3. Brake caliper Figure 1. Caliper Mounting Bolts (Left Side) Dyna and Sportster 3 1 2 is04470 1. Pinch bolt nut 2. Axle 3. Pinch bolt Figure 2. Front Wheel Mounting (Dyna and Sportster Except FXDWG-Right Side) 5. See Figure 3. Obtain the new right (1) and left (2) chrome spacers from kit and install. 6. Apply a light coat of ANTI-SEIZE LUBRICANT (Harley- Davidson Part Number 98960-97) to the axle.
7. Place wheel between sliders and install axle. Verify that axle spacers on right and left side are properly installed. 8. See Figure 3. Install the washer (F), lockwasher (E) and nut (D) onto threaded end of axle (A). 9. In order to properly align the front fork, perform the fol- lowing: a. On the right side of the wheel, insert a 7/16 inch drill bit through the hole in the axle. While holding axle stationary, tighten axle nut to 50-55 ft-lbs (61.0-74.6 Nm) . b. Pull fork leg so that it just contacts drill bit. Tighten according to the following: c. Refer to Figure 2. Tighten the Axle Pinch Bolt Nut to 25-30 ft-lbs (33.9-40.7 Nm) . d. Remove drill bit from axle hole. 10. Follow instructions in Service Manual and install brake caliper to the sliders noting the following: •Loosely install long bolt to the top hole on fork leg. Install the short mounting bolt to the bottom hole and tighten to 28-38 ft-lb (38.0-51.5 Nm) . •Final tighten top bolt to 28-38 ft-lbs (38.0-51.5 Nm) . 11. Repeat Step 10 to install brake caliper on opposite side of wheel. After servicing brakes and before moving motorcycle, pump brakes to build brake system pressure. Insufficient pressure can adversely affect brake performance, which could result in death or serious injury. (00279a) 12. Pump brake lever to move pistons out until they contact both brake pads. Verify piston location against pads

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1. Turn off the ignition switch before proceeding. 2. Select a convenient mounting location for the Bosch sensor. In general, the sensor should be mounted as close to the exhaust valve or exhaust manifold as practical. When choosing a mounting location, allow several inches clearance for the sensor wire harness. The wire harness must exit straight out from the sensor. Do not loop the harness back onto the sensor body. The sensor responds to oxygen pressure. Excessive backpressure will cause a reading error. For turbocharged applications, you must mount the sensor downstream of the turbo. 3. For temporary use during dyno tuning, you can mount the Bosch wide-band sensor in place of one of the original equipment rear oxygen sensors (after the catalytic converter). You can also use a sniffer in the tailpipe. For permanent mounting, an 18 x 1.5 mm weld nut must be welded onto the exhaust pipe. After welding, run an 18 x 1.5 mm tap through the threads. Failure to clean the threads may result in sensor damage. Note that most automotive muffler shops are familiar with oxygen sensor weld nut installation on custom pipes. Do not install the sensor until after the free air calibration procedure described in the following section. Always use an anti-seize lubricant such as Permatex 133A on the sensor threads. 4. Install the WEGO II unit. The WEGO II unit should be mounted where the LCD display will be visible during testing. You can secure the WEGO II unit with Velcro tape strips. 5. Connect the Bosch sensor to the 6 pin mating connector on the WEGO II wire harness. 6. Refer to Figure 1. Connect the black WEGO II wire to frame ground using the supplied ring terminal. Try to use an existing wire harness ground location. Do not extend the WEGO II ground wire or ground the WEGO II to the battery minus terminal or to the engine. 7. Connect the red WEGO II wire to switched +12 volt power. You can usually find switched +12V power at an accessory fuse on the fuse block. You can use the supplied fuse tap and 3/16″ female crimp terminal for this purpose